APPENDIX A: COMMUNICATION RECORDS
MS DEQ - Chromcraft Furniture, MS
EC/R Incorporated Providing Environmental Technical Support Since 1989 

501 Eastowne Dr., Suite 250  Chapel Hill, North Carolina 27514 

Telephone: (919) 484-0222  Fax: (919) 484-0122

TELECOMMUNICATION 

DATE: April 4, 2013 

CALLER: Jeff Harris 

COMPANY: EC/R Inc. 

TELEPHONE NO. 919/484-0222 x335 

PERSON CALLED: Ms. Susan Holden 

COMPANY: MS DEQ, Emission Inventory Group 

TELEPHONE NO. 601-961-5276 

SUBJECT: Emissions from Foam Production at Chromcraft Furniture, Senatobia, MS 

 I spoke with Ms. Holden regarding availability of current emissions information from 

Chromcraft Furniture in Senatobia, MS. She stated that the 2011 emisisons inventory is currently being 

prepared, and agreed to investigate and provide the most current information available. Ms. Holden 

spoke with personnel in the emissions inventory, permitting, and compliance groups of MS DEQ and 

found the following information: 

1) The current emissions inventory shows similar emissions from foam production processes to 

those included in the 2005 NEI. These emissions are approximately half a ton per year of 

unspeciated VOC. However, these VOC are largely emitted by a gluing booth in the foam 

production area of the facility. Gluing operations are classifiesd as foam fabrication and thus 

are not considered to be emissions from the foam production process. 

2) Ms. Holden provided an MSDS for the mixture used in the foam molding process, and stated 

that estimated emissions of the mixture from the foam production process are 0.0014 tons per 

year. Speciated emissions for the HAP components of the mixture are calculated below based 

on this estimate and the information in the MSDS. 

Chromcraft Furniture – 2011 Foam Production Speciated Emission Calculations

HAP Component Mixture Content1 Emissions (tpy)2

2,4 Toluene Diisocyanate 68% 0.00095

Methylene diphenyl diisocyanate 15% 0.00021

1Upper bound concentration estimates are assumed for these components to be conservative.

2 Calculated as total emissions (0.0014 tpy) multipled by the mixture content fraction (e.g., 0.0014*0.68)

Attachments: Original e-mail from Ms. Holden and MSDS.
1

Jeff Harris

From: Susan_Holden@deq.state.ms.us

Sent: Thursday, April 04, 2013 3:09 PM

To: harris.jeff@ecrweb.com

Subject: RE: Chromcraft Furniture MS Permit No. 2600-00003

Attachments: chromcraft tdi msds.PDF

Attached is the MSDS for the Bayer Isocyanate Mixture which Chromcraft used in 2011. 

The upper bound for 584849, 2,4 Toluene Diisocyanate, is 68 %. The upper bound for 91087, 2,6 Toluene Diisocyanate, is 17%. 

It also has these components. 

The upper bound for 101688, 4,4 Diphenylmethane Diisocyanate, is 15%. The upper bound for 26447405, 2,2 2,4 Diphenylmethane Diisocyanate, is 10%. The upper bound for 9016879, Higher Oligomers of MDI, is 15%. 

The total emissions from this product are 0.0014 tons per year. The total of the upper bounds are 125%, but since some are not haps, you may want to assign the maximum upper bound 

to the haps. 

Susan L. Holden, P.E. 

(601) 961-5276 

Mississippi Department of Environmental Quality 

P.O. Box 2261 

Jackson, MS 39225 
I. PRODUCT IDENTIFICATION: V

PRODUCT NAME

PRODUCT CODE

CHEMICAL FAMILY

CHEMICAL NAME

FORMULA

Mondur T—422

V

E—422

Aromatic Isocyanate

Toluene Diisocyanate (TDI) — Diphenylmethane Diisocyanate

(MDI) Blend

Not Applicable

II. HAZARDOUS INGREDIENTS

.005

.036.020

Product Code: E—422

Approval date: 05/02/94

MSDS Page 1

Continued on next page

INGREDIENT NAME

/CAS NUMBER EXPOSURE LIMITS CONCENTRATION (7.)

2,4—To luene Di isocyanate

584—84—9 OSHA : ppm TWA * Upper bound 68

mg!m3 TWA

ppm STEL *

.140 mg/m3 STEL

ACGIH: .005 ppm TWA

.036 tng/m3 TWA

.020 ppm STEL

140 mg/m3 STEL,

* These limits are based on those promulgated by the 1989 OSHA Air Contaminants

Standard 29 CFR 1910.1000. For Section 302 and 313 SARA information refer

to page 6, Section IX, SARA.

26—To1uene Dilsocyanate

91—08—7 OSHA : Not Established Upper bound 177.

ACGIH: Not Established

There are no established guidelines for the 2,6—TDI isomer. However, MILES

recommends the established 2,4—TDI guideline limits for the 2,6—TDI isomer.For Section 302 and 313 SARA information refer to Page 6, Section IX, SARA.
26447—40—5 OSHA : Not Established

ACGIH: Not Established

Higher Oligomers of MDI

9016—87—9 OSHA : Not Established

ACGIH.: Not Established

III. PHYSICAL PROPERTIES:

Upper bound 10%

Upper bound 15%

PHYSICAL FORM

COLOR

ODOR

ODOR THRESHOLD

pH

BOILING POINT

MELTING/FREEZING POINT....:

SOLUBILITY IN WATER

SPECIFIC GRAVITY

BULK DENSITY

% VOLATILE BY VOLUME

VAPOR PRESSURE

VAPOR DENSITY

Liquid

Dark Brown

Sharp, pungent (odor threshold greater than TLV)Greater than TLV of 0.005 ppm for TDI

Not Applicable

Not. Established for Blend; Approx. 484 F (251 c) for TDI; Approx. 406 F (208 C) at 5 mmHg for MDI.

Not EstabLished for Blend

Not soluble. TDI and MDI react slowly with water

to liberate C02 gas.

1.23 @ 77 F (25 c)

10.26 lbs/gal

Negligible

Approx. 0.025 mtn Kg @ 77 F (25 C) for TDI; Less

than 10—5 nnnHg @ 77 F (25 C) for MDI

6.0 for TDI; 8.5 for MDI (Air 1)

IV. FIRE AND EXPLOSION DATA:

FLASH POINT

FLAMMABLE LIMITS:

UPPER EXPLOSIVE LIMIT (UEL) (7.): 9.5 TDI

LOWER EXPLOSIVE LIMIT (LEL) (7.): 0.9% TDI

EXTINGUISHING MEDIA

spray for large fires.

Product Code: E-422

Approval date: 05/02/94

MSDS Page 2

Continued on next page

275.0 F (135.0 C) Pensky—Martens Closed Cup

(ASTM D—93)

Dry Chemical; Carbon Dioxide; Foam; Water
MS DEQ - Flexible Foam, MS
EC/R Incorporated Providing Environmental Technical Support Since 1989 

501 Eastowne Dr., Suite 250  Chapel Hill, North Carolina 27514 

Telephone: (919) 484-0222  Fax: (919) 484-0122

TELECOMMUNICATION 

DATE: July 23, 2012 

CALLER: Jeff Harris 

COMPANY: EC/R Inc. 

TELEPHONE NO. 919/484-0222 x335 

PERSON CALLED: Ms. Carla Brown 

COMPANY: MS DEQ 

TELEPHONE NO. 601-961-5235 

SUBJECT: Emissions from Foam Production at Flexible Foam Products Inc. Tupelo, MS 

 I spoke with Ms. Brown regarding availability of current emissions information from Flexible 

Foam Products Inc.in Tupelo, MS. She provided a copy of the current MS inventory for the facility, 

which shows no current emissions of epichlorohydrin, acrolein, diethanolamine, propylene dichloride, or 

1,1,2,2-tetrachloroethane. Pollutants not present in the inventory were not included in the modeling file 

for the facility, and FPUF emissions in the EIS data used in the dataset were updated using emissions 

values in the MSDEQ inventory.

Attachments: Original e-mail from Ms. Brown and MS DEQ Inventory for the facility.
1

Jeff Harris

From: Carla_Brown@deq.state.ms.us

Sent: Monday, July 23, 2012 4:19 PM

To: harris.jeff@ecrweb.com

Subject: Re: Request for Facility Information - Flexible Foam Products Inc. Tupelo, MS

Attachments: Flexible_Foam_Inventory.pdf

Jeff, 

Sorry for the delay. I actually thought I had emailed you that information earlier this morning. I'm attaching a copy of the 

annual emissions report they submitted for actual emissions in 2011. Let me know if you need some additional 

information. 

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 

Carla Brown, P.E. 

Chemical Branch Manager 

Environmental Permits Division 

Office of Pollution Control 

Mississippi Department of Environmental Quality 

P.O. Box 2261 

Jackson, MS 39225 

cbrown@deq.ms.gov 

Phone: (601) 961-5235 

Fax; (601) 961-5703 

From: "Jeff Harris" <harris.jeff@ecrweb.com>

To: <CARLA_BROWN@DEQ.STATE.MS.US>

Date: 07/23/2012 02:17 PM

Subject: Request for Facility Information - Flexible Foam Products Inc. Tupelo, MS

Carla, 

As we discussed on the phone last week, I am Jeff Harris, an engineer with EC/R incorporated in Chapel Hill, NC.   

We are assisting the USEPA with the Risk and Technology Review for the Flexible Polyurethane Foam source category. 

I appreciate the time you took to speak with me last week. I was wondering if you had any luck finding any more recent emissions

for this facility: 

Flexible Foam Products Inc. 

1665 South Veterans Blvd 

Tupelo, MS 

MS Permit No.: 1540‐00046 

As I mentioned on the phone, we are particularly interested in emissions from the polyurethane foam production process, including

associated storage tanks and equipment leaks. 

The emissions information we have been using for our modeling is somewhat dated, and is compiled from the 2005 and 2008 EPA

emission inventories. 

We would very much like to verify it against any more recent emissions data you may have. 

Thank you for any assistance you can provide, 

Jeff

_____________________

Jeff Harris

EC/R Incorporated 












VA DEQ - IAC Strasburg, VA
EC/R Incorporated Providing Environmental Technical Support Since 1989 

501 Eastowne Dr., Suite 250  Chapel Hill, North Carolina 27514 

Telephone: (919) 484-0222  Fax: (919) 484-0122

TELECOMMUNICATION 

DATE: July 17, 2012 

CALLER: Jeff Harris 

COMPANY: EC/R Inc. 

TELEPHONE NO. 919/484-0222 x335 

PERSON CALLED: Mr. Jeremy Funkhauser 

COMPANY: VA DEQ 

TELEPHONE NO. 540-574-7820 

SUBJECT: Emissions from IAC Strasburg, Strasburg, VA 

 I spoke with Mr. Funkhauser regarding availability of current emissions information from IAC 

Strasburg in Strasburg, VA. He provided a copy of the current VA inventory for the facility, showing that 

glycol ether emissions from the facility are related to surface coating operations (two paint spray booths 

and one glue/paint application line) rather than foam injection. Since surface coating operations are not 

part of the foam production source category, these emissions were not included in the modeling file for 

the facility.

Attachments: Original e-mail from Mr. Funkhauser and VA DEQ Inventory for the facility.
1

Jeff Harris

From: Funkhouser, Jeremy (DEQ) <Jeremy.Funkhouser@deq.virginia.gov>

Sent: Tuesday, July 17, 2012 12:10 PM

To: 'harris.jeff@ecrweb.com'

Subject: Glycol ether emissions from IAC Strasburg

Attachments: 80964 IAC EI 2008.pdf; 80964 IAC EI 2011.pdf

Jeff,

  

From what I’ve been able to find so far it appears the glycol ether emissions from IAC Strasburg (Reg. No. 80964) are

related to surface coating operations (two paint spray booths and one glue/paint application line) rather than foam

injection.

  

Attached are the emissions inventory break downs for 2011 and 2008 (the date of your inventory summary).

Total emissions of glycol ether in 2008 are listed as 1.117 tons/yr, and emissions in 2011 are listed as 0.499 tons/yr.

  

Let me know if this is helpful, or if you require additional information.

  

  

Jeremy Funkhouser

Air Permit Writer

DEQ - Valley Regional Office

P.O. Box 3000

Harrisonburg, VA 22801

Phone: 540-574-7820

Fax: 540-574-7878

E-mail: jeremy.funkhouser@deq.virginia.gov

  

  

  
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 1 of 16

Registration No: 80964 FIPS County Code: 171 Year of Emissions: 2011

Plant Name: IAC Strasburg LLC Plant ID: 00058 Last Annual Update: 2011

GENERAL INFORMATION

Facility Name:

Location Address:

Mailing Address:

Anuual Update Contact:

Phone Number: (540) 465 - 3741

Principal Product: plastics

Gray, Chris

806 E Queen Street

Strasburg VA 22657

806 E Queen St

Strasburg VA 22657

IAC Strasburg LLC

Comments: Chris Gray is the Plant Manager for both the Winchester and the Strasburg facilities - see letter dated 11/2/04. krs

Facility Emissions Pollutant Emissions Value (tpy) Allowable Value Units

PM 10

VOC

PM

GLYET

6MCYN

 0.0896505010

 3.7416300000

 0.0306609304

 0.4991310000

 0.0000000000

STACK INFORMATION: 2

Stack Height(ft):

Exit Gas Temperature(F):

Gas Flow Rate(ACFM):

Exit Gas Velocity(ft/sec):

Plume Height(ft): 30

Permitted Equipment: N

0

0

0

0

0

Stack Diameter(ft):

Stack Type: F

VOC 0.0000000000

POINT INFORMATION: Description: Plant 1 Mold Shop Parts Washer (CC1)

Design Capacity & Units: 0

21

State Sensitive:

Permitted Equipment: N

N

Number:

Stack Emissions Pollutant Emissions Value (tpy) Allowable Value Units

Description: Plant 1 Mold Shop Parts Washer (CC1) UTM Zone:

UTM Horizontal(KM):

UTM Vertical(KM):

GEP Stack Height: 0

GEP Building Height: 0

GEP Building Length: 0

GEP Bulding Width:

Rough Terrain: N

17

4317.9

729.1

0

Elevation (ft above MSL): 560

Number:

UTM Zone:

UTM Vertical (KM):

UTM Horizontal (KM):

4317.9

729.1

 Latitude: 38 58 55 

 Longitude: -78 21 19 

Property Area (Acres):

No. of Employees:

Primary SIC Code:

388

26.4

3089

o ' "

o ' "

17
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 2 of 16

STACK INFORMATION: 3

Per

% Throughput: DEC-FEB: 25 MAR-MAY: 25 JUN-AUG: 25 SEP-NOV: 25

Operating Schedule: Hours/Day: 24 Days/Week: 7 Hours/Year: 8760

Point Emissions Pollutant Emissions Value (tpy) Allowable Value Units 

VOC 0.0000000000

SEGMENT INFORMATION: 1 Description:

Source Classification Code: 49099999

Actual Annual Throughput:

Max. Hourly Operation Rate: 0

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

0

N

CC1 -Parts Washer

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Identify the Process and Solvent in Comments

Heat Content (MMBTU): 0

SCC Units: Tons Solvent Consumed

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments:

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

VOC Federal factor (auto calc) 2000.0000000000 0.0000000000

Number:

Space Heat (%):

0

Air Program Sub Part

Number: Description: Mold-CLN
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 3 of 16

Stack Height(ft):

Exit Gas Temperature(F):

Gas Flow Rate(ACFM):

Exit Gas Velocity(ft/sec):

Plume Height(ft): 30

Permitted Equipment: N

0

0

0

0

0

Stack Diameter(ft):

Stack Type: F

VOC 0.6000000000

POINT INFORMATION: Description: Mold-CLN

Design Capacity & Units: 0

Per

% Throughput: DEC-FEB: 25 MAR-MAY: 25 JUN-AUG: 25 SEP-NOV: 25

Operating Schedule: Hours/Day: 24 Days/Week: 7 Hours/Year: 8760

Point Emissions Pollutant Emissions Value (tpy) Allowable Value Units 

VOC 0.6000000000

SEGMENT INFORMATION: 1 Description:

Source Classification Code: 49099999

Actual Annual Throughput:

Max. Hourly Operation Rate: 0

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

.6

N

MOLD-CLN

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Identify the Process and Solvent in Comments

Heat Content (MMBTU): 0

SCC Units: Tons Solvent Consumed

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments:

Segment Comments:

Number:

22

State Sensitive:

Permitted Equipment:

Space Heat (%):

N

0

N

Air Program Sub Part

Number:

Stack Emissions Pollutant Emissions Value (tpy) Allowable Value Units

UTM Zone:

UTM Horizontal(KM):

UTM Vertical(KM):

GEP Stack Height: 0

GEP Building Height: 0

GEP Building Length: 0

GEP Bulding Width:

Rough Terrain: N

17

4317.9

729.1

0

Elevation (ft above MSL): 560
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 4 of 16

STACK INFORMATION: 4

Stack Height(ft):

Exit Gas Temperature(F):

Gas Flow Rate(ACFM):

Exit Gas Velocity(ft/sec):

Plume Height(ft): 0

Permitted Equipment: Y

20

2.5

70

3600

12.22

Stack Diameter(ft):

Stack Type: V

GLYET

PM

PM 10

VOC

 0.3399150000

 0.0220104294

 0.0150000000

 0.8100000000

POINT INFORMATION: Description: PL1-PAINT 1B

Design Capacity & Units: 1

Per

GALLONS

HOUR

% Throughput: DEC-FEB: 25 MAR-MAY: 25 JUN-AUG: 25 SEP-NOV: 25

Operating Schedule: Hours/Day: 24 Days/Week: 7 Hours/Year: 8760

Point Emissions Pollutant Emissions Value (tpy) Allowable Value Units 

GLYET

PM

PM 10

VOC

 0.3399150000

 0.0220104294

 0.0150000000

 0.8100000000

 1.2700000000

 2.4000000000

 1.2700000000

 2.4000000000

 2.7000000000

lbs/hr

tons/yr

lbs/hr

tons/yr

tons/yr

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

VOC Federal factor (auto calc) 2000.0000000000 0.6000000000

23

State Sensitive:

Permitted Equipment:

Space Heat (%):

Y

0

N

Air Program

SIP

Sub Part

Number:

Stack Emissions Pollutant Emissions Value (tpy) Allowable Value Units

Description: PL1-PAINT 1B UTM Zone:

UTM Horizontal(KM):

UTM Vertical(KM):

GEP Stack Height: 0

GEP Building Height: 0

GEP Building Length: 0

GEP Bulding Width:

Rough Terrain: N

17

4317.9

729.1

0

Elevation (ft above MSL): 560

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 5 of 16

STACK INFORMATION: 6

Stack Height(ft):

Exit Gas Temperature(F):

Gas Flow Rate(ACFM):

Exit Gas Velocity(ft/sec):

Plume Height(ft): 30

Permitted Equipment: Y

0

0

70

0

0

Stack Diameter(ft):

Stack Type: F

SEGMENT INFORMATION: 1 Description:

Source Classification Code: 40200210

Actual Annual Throughput:

Max. Hourly Operation Rate: 1

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

1333

Y

PL1-PAINT 1B

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Paint: Water-base

Heat Content (MMBTU): 0

SCC Units: Gallons of Coating

3800

Gallons Coating

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments: HVLP guns

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

PM

PM 10

GLYET

VOC

 0.0220104294

 0.0150000000

 0.3399150000

 0.8100000000

058 = Mat or Panel Filter

058 = Mat or Panel Filter

 3.6290000000

 0.0000000000

 0.5100000000

 0.0000000000

058

058

99.09

99.09

Supplied factor (auto calc)

Material balance (user calc)

Supplied factor (auto calc)

Material balance (user calc)

HVLP guns - transfer eff. and 97.4 filter eff.

HVLP guns - transfer eff. and 97.4 filter eff.

Number:

Description: PL2-PAINT-R/T-020 UTM Zone:

UTM Horizontal(KM):

UTM Vertical(KM):

GEP Stack Height: 0

GEP Building Height: 0

GEP Building Length: 0

GEP Bulding Width:

Rough Terrain: N

17

4317.9

729.1

0

Elevation (ft above MSL): 560

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 6 of 16

6MCYN

GLYET

PM

PM 10

VOC

 0.0000000000

 0.1592160000

 0.0086505010

 0.0086505010

 0.4016300000

POINT INFORMATION: Description: PL2-PAINT-R/T-020

Design Capacity & Units: 5

Per

GALLONS

HOUR

% Throughput: DEC-FEB: 25 MAR-MAY: 25 JUN-AUG: 25 SEP-NOV: 25

Operating Schedule: Hours/Day: 24 Days/Week: 7 Hours/Year: 8760

Point Emissions Pollutant Emissions Value (tpy) Allowable Value Units 

6MCYN

GLYET

PM

PM 10

VOC

 0.0000000000

 0.1592160000

 0.0086505010

 0.0086505010

 0.4016300000

 6.6800000000

 6.6000000000

 6.6800000000

 6.6000000000

 5.2000000000

lbs/hr

tons/yr

lbs/hr

tons/yr

tons/yr

SEGMENT INFORMATION: 1 Description:

Source Classification Code: 40200210

Actual Annual Throughput:

Max. Hourly Operation Rate: 5

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

496

Y

R/T-United Paint Dark Slate, Med. Slate, or Med. Pebble Beige

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Paint: Water-base

Heat Content (MMBTU): 0

SCC Units: Gallons of Coating

9000

Gallons Coating

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments: HVLP guns

Segment Comments:

Number:

25

State Sensitive:

Permitted Equipment:

Space Heat (%):

Y

0

N

Air Program

SIP

Sub Part

Number:

Stack Emissions Pollutant Emissions Value (tpy) Allowable Value Units
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 7 of 16

SEGMENT INFORMATION:

SEGMENT INFORMATION:

Description:

Description:

2

3

Source Classification Code: 40200110

Actual Annual Throughput:

Max. Hourly Operation Rate: 5

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

0

Y

GM020-Red Spot Adhesion Promoter

GM020-Red Spot Med. Steel Gray

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Paint: Solvent-base

Heat Content (MMBTU): 0

SCC Units: Gallons of Coating

30

Gallons Coating

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments: HVLP guns

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

PM

PM 10

GLYET

VOC

PM

PM 10

VOC

 0.0085058792

 0.0085058792

 0.1592160000

 0.3820000000

 0.0000000000

 0.0000000000

 0.0000000000

058 = Mat or Panel Filter

058 = Mat or Panel Filter

058 = Mat or Panel Filter

058 = Mat or Panel Filter

 3.7690000000

 3.7690000000

 0.6420000000

 0.0000000000

 2.5440000000

 2.5440000000

 6.1000000000

058

058

058

058

99.09

99.09

99.09

99.09

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

Material balance (user calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

HVLP guns - transfer eff. and 97.4 fitler eff.

HVLP guns - transfer eff. and 97.4 filter eff.

HVLP guns - transfer eff. and 97.4 filter eff.

HVLP guns - transfer eff. and 97.4 filter eff.

Number:

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 8 of 16

SEGMENT INFORMATION: 4 Description:

Source Classification Code:

Source Classification Code:

40200210

40200210

Actual Annual Throughput:

Actual Annual Throughput:

Max. Hourly Operation Rate:

Max. Hourly Operation Rate:

5

5

State Sensitive:

State Sensitive:

N

N

Permitted Equipment:

Permitted Equipment:

Pollution Prevention:

Pollution Prevention:

N

N

Insignificant Activity:

Insignificant Activity:

N

N

0

0

Y

Y

GM020-United Paint Dark Gray Metallic

SCC Description:

SCC Description:

Trace%: 

Trace%: 

0

0

 Ash%:

 Ash%:

0

0

Sulfur%:

Sulfur%:

0

0

Paint: Water-base

Paint: Water-base

Heat Content (MMBTU): 

Heat Content (MMBTU): 

0

0

SCC Units:

SCC Units:

Gallons of Coating

Gallons of Coating

90

610

Gallons Coating

Gallons Coating

Throughput Limit:

Throughput Limit:

Throughput Unit:

Throughput Unit:

Pollution Prevention Comments: HVLP guns

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

PM

PM 10

GLYET

VOC

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

058 = Mat or Panel Filter

058 = Mat or Panel Filter

 3.4000000000

 3.4000000000

 0.4960000000

 1.1900000000

058

058

99.09

99.09

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

HVLP guns - transfer eff. and 97.4 filter eff.

HVLP guns - transfer eff. and 97.4 filter eff.

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 9 of 16

SEGMENT INFORMATION: 5 Description:

Source Classification Code: 40200210

Actual Annual Throughput:

Max. Hourly Operation Rate: 5

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

0

Y

GM020-United Paint Very Dk. Steel Gray

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Paint: Water-base

Heat Content (MMBTU): 0

SCC Units: Gallons of Coating

155

Gallons Coating

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments:

Pollution Prevention Comments:

HVLP guns

HVLP guns

Segment Comments:

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

PM

PM 10

VOC

PM

PM 10

VOC

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

058 = Mat or Panel Filter

058 = Mat or Panel Filter

058 = Mat or Panel Filter

058 = Mat or Panel Filter

 3.5080000000

 3.5080000000

 0.4600000000

 3.8150000000

 3.8150000000

 0.3800000000

058

058

058

058

99.09

99.09

99.09

99.09

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

HVLP guns - transfer eff. and 97.4 filter eff.

HVLP guns - transfer eff. and 97.4 filter eff.

HVLP guns - transfer eff. and 97.4 filter eff.

HVLP guns - transfer eff. and 97.4 filter eff.

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 10 of 16

SEGMENT INFORMATION:

SEGMENT INFORMATION:

Description:

Description:

6

7

Source Classification Code:

Source Classification Code:

40200110

40200110

Actual Annual Throughput:

Actual Annual Throughput:

Max. Hourly Operation Rate:

Max. Hourly Operation Rate:

5

5

State Sensitive:

State Sensitive:

N

N

Permitted Equipment:

Permitted Equipment:

Pollution Prevention:

Pollution Prevention:

N

N

Insignificant Activity:

Insignificant Activity:

N

N

0

6.5

Y

Y

GM020-United Paint Crosslinker

Ford Bus Grille - Argent or Black/QTP Reducer mixture - NB Coatings

SCC Description:

SCC Description:

Trace%: 

Trace%: 

0

0

 Ash%:

 Ash%:

0

0

Sulfur%:

Sulfur%:

0

0

Paint: Solvent-base

Paint: Solvent-base

Heat Content (MMBTU): 

Heat Content (MMBTU): 

0

0

SCC Units:

SCC Units:

Gallons of Coating

Gallons of Coating

100

200

Gallons Coating

Gallons Coating

Throughput Limit:

Throughput Limit:

Throughput Unit:

Throughput Unit:

Pollution Prevention Comments: HVLP guns

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

PM

PM 10

6MCYN

VOC

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

058 = Mat or Panel Filter

058 = Mat or Panel Filter

 4.8288000000

 4.8288000000

 0.0017820000

 4.0800000000

058

058

99.09

99.09

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

HVLP guns - transfer eff. and 97.4 filter eff.

HVLP guns - transfer eff. and 97.4 filter eff.

Number:

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 11 of 16

STACK INFORMATION: 11

Stack Height(ft):

Exit Gas Temperature(F):

Gas Flow Rate(ACFM):

Exit Gas Velocity(ft/sec):

Plume Height(ft): 0

Permitted Equipment: N

11

1

70

1

.02

Stack Diameter(ft):

Stack Type: V

VOC 0.0000000000

POINT INFORMATION: Description: Rotocasts 1 and 2

Design Capacity & Units: 0

Per

% Throughput: DEC-FEB: 25 MAR-MAY: 25 JUN-AUG: 25 SEP-NOV: 25

Operating Schedule: Hours/Day: 24 Days/Week: 7 Hours/Year: 8760

Point Emissions Pollutant Emissions Value (tpy) Allowable Value Units 

VOC 0.0000000000

Pollution Prevention Comments: HVLP guns

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

PM

PM 10

VOC

 0.0001446218

 0.0001446218

 0.0196300000

058 = Mat or Panel Filter

058 = Mat or Panel Filter

 4.8900000000

 4.8900000000

 6.0400000000

058

058

99.09

99.09

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

HVLP guns - transfer eff. and 97.4 filters

HVLP guns - transfer eff. and 97.4 filters

30

State Sensitive:

Permitted Equipment:

Space Heat (%):

N

0

N

Air Program Sub Part

Number:

Stack Emissions Pollutant Emissions Value (tpy) Allowable Value Units

Description: Rotocasts 1 and 2 UTM Zone:

UTM Horizontal(KM):

UTM Vertical(KM):

GEP Stack Height: 0

GEP Building Height: 0

GEP Building Length: 0

GEP Bulding Width:

Rough Terrain: N

17

4317.9

729.1

0

Elevation (ft above MSL): 560

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 12 of 16

STACK INFORMATION: 12

Stack Height(ft):

Exit Gas Temperature(F):

Gas Flow Rate(ACFM):

Exit Gas Velocity(ft/sec):

Plume Height(ft): 30

Permitted Equipment: N

0

0

0

0

0

Stack Diameter(ft):

Stack Type: F

VOC 0.0000000000

POINT INFORMATION: Description: Paint-CLN

SEGMENT INFORMATION: 1 Description:

Source Classification Code: 49099999

Actual Annual Throughput:

Max. Hourly Operation Rate: 0

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

0

N

ROTOCASTS 1 and 2

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Identify the Process and Solvent in Comments

Heat Content (MMBTU): 0

SCC Units: Tons Solvent Consumed

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments:

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

VOC Federal factor (auto calc) 2000.0000000000 0.0000000000

Number:

Number: 31

Stack Emissions Pollutant Emissions Value (tpy) Allowable Value Units

Description: Paint-CLN UTM Zone:

UTM Horizontal(KM):

UTM Vertical(KM):

GEP Stack Height: 0

GEP Building Height: 0

GEP Building Length: 0

GEP Bulding Width:

Rough Terrain: N

17

4317.9

729.1

0

Elevation (ft above MSL): 560

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 13 of 16

STACK INFORMATION: 14

Design Capacity & Units: 0

Per

% Throughput: DEC-FEB: 25 MAR-MAY: 25 JUN-AUG: 25 SEP-NOV: 25

Operating Schedule: Hours/Day: 24 Days/Week: 7 Hours/Year: 8760

Point Emissions Pollutant Emissions Value (tpy) Allowable Value Units 

VOC 0.0000000000

SEGMENT INFORMATION: 1 Description:

Source Classification Code: 49099999

Actual Annual Throughput:

Max. Hourly Operation Rate: 0

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

0

N

PAINT-CLN

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Identify the Process and Solvent in Comments

Heat Content (MMBTU): 0

SCC Units: Tons Solvent Consumed

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments:

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

VOC Federal factor (auto calc) 2000.0000000000 0.0000000000

Number:

State Sensitive:

Permitted Equipment:

Space Heat (%):

N

0

N

Air Program Sub Part

Number: Description: PL2-GB1-Line 1
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 14 of 16

Stack Height(ft):

Exit Gas Temperature(F):

Gas Flow Rate(ACFM):

Exit Gas Velocity(ft/sec):

Plume Height(ft): 0

Permitted Equipment: Y

20

3.09

140

8000

17.78

Stack Diameter(ft):

Stack Type: V

GLYET

PM

PM 10

VOC

 0.0000000000

 0.0000000000

 0.0660000000

 1.9300000000

POINT INFORMATION: Description: PL2-GB1-Line1

Design Capacity & Units: 5

Per

GALLONS

HOUR

% Throughput: DEC-FEB: 25 MAR-MAY: 25 JUN-AUG: 25 SEP-NOV: 25

Operating Schedule: Hours/Day: 24 Days/Week: 7 Hours/Year: 24

Point Emissions Pollutant Emissions Value (tpy) Allowable Value Units 

GLYET

PM

PM 10

VOC

 0.0000000000

 0.0000000000

 0.0660000000

 1.9300000000 4.3000000000 tons/yr

SEGMENT INFORMATION: 1 Description:

Source Classification Code: 40200110

Actual Annual Throughput:

Max. Hourly Operation Rate: 5

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

0

Y

Chrysler HB/HG Service - Coat-it adhesive A & B

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Paint: Solvent-base

Heat Content (MMBTU): 0

SCC Units: Gallons of Coating

250

Gallons Coating

Throughput Limit:

Throughput Unit:

Number:

32

State Sensitive:

Permitted Equipment:

Space Heat (%):

Y

0

N

Air Program Sub Part

Number:

Stack Emissions Pollutant Emissions Value (tpy) Allowable Value Units

UTM Zone:

UTM Horizontal(KM):

UTM Vertical(KM):

GEP Stack Height: 0

GEP Building Height: 0

GEP Building Length: 0

GEP Bulding Width:

Rough Terrain: N

17

4317.9

729.1

0

Elevation (ft above MSL): 560
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 15 of 16

SEGMENT INFORMATION: 2 Description:

Source Classification Code: 40200210

Actual Annual Throughput:

Max. Hourly Operation Rate: 5

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

0

Y

PN-99 and Chrysler HB/HG - PPG T7944 Trim Bond Heat Activated adhesive

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Paint: Water-base

Heat Content (MMBTU): 0

SCC Units: Gallons of Coating

200

Gallons Adhesive

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments:

Pollution Prevention Comments:

HVLP guns

HVLP guns

Segment Comments:

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

PM

PM 10

VOC

PM

PM 10

VOC

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

058 = Mat or Panel Filter

058 = Mat or Panel Filter

058 = Mat or Panel Filter

058 = Mat or Panel Filter

 4.4500000000

 0.0000000000

 0.0000000000

 4.4300000000

 4.4300000000

 0.1702000000

058

058

058

058

99.09

99.09

99.09

99.09

Supplied factor (auto calc)

Material balance (user calc)

Material balance (user calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

Supplied factor (auto calc)

filter efficiency and HVLP guns - transfer efficiency

filter efficiency and HVLP guns - transfer efficiency

filter efficiency and HVLP gun transfer eff.

filter efficiency and HVLP gun transfer eff.

Number:
Date: 07/17/2012 11:43 AM Commonwealth of Virginia

Department of Environmental Quality

Consolidated Plant Emissions Report

Page 16 of 16

SEGMENT INFORMATION: 3 Description:

Source Classification Code: 40200210

Actual Annual Throughput:

Max. Hourly Operation Rate: 5

State Sensitive: N

Permitted Equipment:

Pollution Prevention: N

Insignificant Activity: N

3685

Y

GMT360 Service - SWVF-NML Ebony, Lt. Cashmere, Lt. Grey, or Dk. Grey

SCC Description:

Trace%: 0 Ash%: 0 Sulfur%: 0

Paint: Water-base

Heat Content (MMBTU): 0

SCC Units: Gallons of Coating

500

Gallons Coating

Throughput Limit:

Throughput Unit:

Pollution Prevention Comments: HVLP guns

Segment Comments:

Segment Emissions 

Pollutant Method Factor A/S/T Primary Secondary Overall Emissions Value Allowable Value Units

 Control Control Efficiency % (tpy) 

PM

PM 10

GLYET

VOC

 0.0000000000

 0.0660000000

 0.0000000000

 1.9300000000

058 = Mat or Panel Filter

058 = Mat or Panel Filter

 0.0000000000

 0.0000000000

 0.0000000000

 0.0000000000

058

058

99.09

99.09

Material balance (user calc)

Material balance (user calc)

Material balance (user calc)

Material balance (user calc)

filter eff. and HVLP gun transfer eff.

filter eff. and HVLP gun transfer eff.

Number:
Communications with 

Polyurethane Foam Association (PFA)
EC/R Incorporated Providing Environmental Technical Support Since 1989 

501 Eastowne Dr., Suite 250  Chapel Hill, North Carolina 27514 

Telephone: (919) 484-0222  Fax: (919) 484-0122

TELECOMMUNICATION 

DATE: March 12, 2013 

CALLER: Jeff Harris 

COMPANY: EC/R Inc. 

TELEPHONE NO. 919/484-0222 x335 

PERSON CALLED: Bob Ludeka 

COMPANY: Polyurethane Foam Association (PFA) 

TELEPHONE NO. 865-657-9840 

SUBJECT: HAP Auxiliary Blowing Agent Usage in the Polyurethane Foam Industry 

 EPA and EC/R staff a spoke with Mr. Luedeka and Jim McIntyre to ask the Polyurethane 

Foam Association (PFA) about current industry practices, including the use of HAP auxiliary 

blowing agents (ABA) in the slabstock polyurethane foam production industry. Mr . Luedeka 

stated that PFA is unaware of any foam producers still using HAP ABA in the United States. He 

said that the few facilities who had continued using HAP ABA after the promulgation of the 

Foam Production MACT and Area Source rules (40 CFR 63 Subparts III and OOOOOO) have 

since discontinued any use of HAP ABA. 

 

a EPA: Kaye Whitfield, Keith Barnett EC/R: Jeff Harris, Lesley Stobert 
June 25, 2013 

Ms. Kaye Whitfield 

Minerals and Manufacturing Group (MMG) (D242-02) 

SPPD/OAQPS 

U.S. Environmental Protection Agency 

Research Triangle Park, NC 27711 

Dear Ms. Whitfield: 

In follow-up to yesterday’s telephone discussion with Jeff Harris, here is a summary of 

the Polyurethane Foam Association’s calculations for annual volume for slabstockprocessed flexible polyurethane foam production in the United States. Calculations were 

based on census production reports submitted by PFA manufacturing member companies 

and results were extrapolated to factor for production of non-member companies that do 

not participate in the census reports. Polyurethane Foam Association estimates are closely 

correlated with separate bi-annual volume estimates issued by the American Chemistry 

Council Center for the Polyurethanes Industry. 

 2005 2006 2007 2008 2009 2010 2011 2012 

Millions pounds 1276 1085 975 935 589 721 769 866 

There is no expectation in the foreseeable future for any new foam production plants that 

would qualify as major sources for HAP emissions. In fact, if existing foam production 

plants that were initially classified as major sources were to be re-assessed based only on 

recent reports of HAP emissions, none would qualify as a major source. 

Sincerely, 

Robert J. Luedeka 

Executive Director